Assembling Transmission
Assembly
Note:
When assembling, apply the specified ATF oil to bearing points and sliding surfaces. Place new brake bands and lined discs of multidisc brake for approx. 1 hour in ATF oil before installing.
52. Position housing (1) in assembly device and secure with bolt (arrow).
53. Screw in screw plugs with a new aluminum seal and tighten to 13 Nm.
54. Insert guide ring (88a), then insert lip seal (88) with the shop-made impact mandrel; the seal lip must be facing the brake band piston cover (arrow).
Note:
The impact mandrel should be shop-made in accordance with the prescribed dimensions.
55. Insert O-ring (arrow) into the groove.
56. Insert O-ring (arrow) into the groove.
57. Insert O-ring (91) into the groove.
58. Insert radial seal (92). Insert aluminum seal (90).
59. Insert O-ring (arrow) into the groove.
60. Coat grooves in supporting flange K2 (79) with grease. Insert Teflon rings (115) and press into the groove until the joint (arrow) stays together.
61. Insert supporting flange (79) in accordance with the hole pattern of the mounting hole; use two bolts approx. 80 mm long for centering.
62. Screw in hexagon bolts (114) and tighten to 11 Nm.
63. Examine thrust body B2 for twist; with thrust body removed, the hole and the tab (arrows) must be in line.
Note:
Thrust bearing B2 brake band guide and brake band piston B2 are installed in different versions.
Versions are listed below.
Version "A"
Thrust bearing B2 together with brake band guide without oil drain hole (arrow).
Installed up to transmission end no.377 682.
Version "B"
Thrust bearing B2 with oil drain hole pointing downwards (arrow) only in combination with brake band guide with additional oil drain hole (arrow).
Installed as from transmission end no.377 683.
Version "C"
Thrust bearing B2 with enlarged stroke identified by lack of annular groove (arrow), in combination with brake band piston B2 with reduced contact stroke: dimension "a" = 2.6 - 2.8 mm instead of 3.4 - 3.6 mm.
Installed as from transmission end no.451 986.
Note:
Install thrust bearing B2 with enlarged stroke only together with the modified brake band piston B2.
The previous thrust bearing can be combined with the old and new brake band pistons.
64. Insert thrust body B2 (29) with the tab facing upwards.
65. Insert thrust washer (113) in such a way that tab for anti-twist lock (arrow) is located in the housing.
66. Re-check seating of Teflon rings on supporting flange (79).
67. Compress brake band B2 (27) at the supporting tabs as far as possible, and insert into housing.
Note:
The brake band can be held together by means of the retaining element (23) to facilitate installation.
68. Fit clutch K2 (100) onto the gear set.
030 Assembly pedestal 126 589 00 35 00
69. Insert gear set into transmission housing, turning input shaft (87).
70. Position transmission with input shaft (87) pointing vertically upwards.
71. Check installation position of gear set. The gear set is correctly inserted when the top edge of the connection carrier (arrow) is lower than the contact face of the externally-toothed disc LB3.
72. Assemble front cover with primary pump.
73. Insert damping spring (134), installed as from transmission end.
Note:
For transmissions of previous design, a repair version damping spring (Part no.123 993 05 15 can be installed.
74. Place plastic base under the Belteville spring washer of the multi-disc brake B3.
75. Assemble discs for multi-disc brake B3 and insert individually.
All models
1. Internally-toothed disc
3. Externally-toothed disc
7. Belleville spring washer
12. Piston LB3
76. Measuring and compensating play L" of multi-disc brake B3.
Determining dimension "a".
Place parallel support (029) onto the machined surface, measure with the depth gauge to the outer edge of Belleville spring washer (85) or of the shim (5).
Determining dimension "b".
Place parallel support (029) onto the piston of the multi-disc brake (arrows), measure with the depth gauge to gasket (11). The difference between the two measurements corresponds to the play "L".
Set play "L" to the nominal value of 1.5 - 2.0 mm. Compensation is effected by means of externally-toothed discs, available in various thicknesses, or with the shim.
77. Coat groove in input shaft (87) with grease. Insert lubricating pressure rings (99) and press into the groove so that the joint stays together.
Note:
Transmission 722.417 is fitted with only one lubricating pressure ring (99) and has an additional bearing point in the front cover.
78. Attach assembly lock (arrow) to brake band B1 (30).
79. Insert clutch K1 (83), turning it so that teeth mesh.
80. Insert brake band B1 (30) in such a way that pin of assembly lock (arrow) is facing thrust body B1.
81. Check O-rings and replace if necessary. Next, insert thrust body B1 (31) with thrust pin and screw in screw plug (33) or overload protection switch (33b), tightening to 70 Nm.
82. Insert brake band guide (34), ensuring that locating studs engage in the holes in the housing, and press in until it is felt to lock into place.
Note:
As from transmission end no.180 000, a brake band guide with a larger through-hole for the brake band piston is installed with removable thrust pin.
83. Measuring and compensating end play "B" for clutch K1
End play "B": 0.6 - 1.0 mm.
95 Shims
96 Thrust washer
97 Axial bearing
Place gasket (11) onto the front cover (10).
Place parallel support (029) onto the flange (arrow).
Measure with depth gauge from the parallel support to gasket (dimension "b").
Place parallel support (029) onto the machined surface of the transmission housing. Measure with depth gauge from the parallel support to the contact face in clutch K1 (83) (dimension "a").
Hold shim (95), thrust washer (96) and axial bearing (97) together and measure dimension "c" with a calliper slide.
Dimension "b" and "c" deducted from dimension "a" produces the end play "B" of clutch K1. The end play can be adjusted by inserting appropriate shims (95, thicknesses 0.1, 0.2, 0.5 mm).
Pay attention to sequence in which thrust washers and shims are installed.
84. Insert measured shims, thrust washers and axial bearings one after the other into clutch K1.
85. Insert Teflon rings (9) with grease. Ensure that joint of rings (arrow) stays together. If necessary, remove rings again and shape to a smaller diameter.
86. Insert front cover (10) with gasket. Tighten bolts (18) to 13 Nm.
Note:
Fit on cover (10) in such a way that the two passages in the cover are open.
The gasket can be used several times, but must not be coated with sealant. In contrast, the bolts (18) should be coated lightly with a non-hardening sealant.
87. Turn assembly device in such a way that input shaft (68) is pointing upwards.
88. Push retaining ring (116) onto the input shaft (68) as far as its groove.
89. Fit on helical gear (78) and insert snap ring (123).
90. Insert O-ring (48).
91. Insert centrifugal governor (50), rotating bearing ring so that the lug meshes into the groove in the housing (see sectional view, arrow). Insert retaining ring (43) and ensure that it engages in the groove.
92. Insert cover (46) and install retaining ring (47) with the help of a screwdriver.. Next, pull the cover outwards so that its entire circumference rests against the retaining ring.
93. Insert intermediate plate (19) and install O-ring (18).
94. Fit on secondary pump (20) and tighten hexagon socket bolts (45) to 8 Nm.
Note:
On vehicles without secondary pump as of June '91, screw on cover.
Tightening torque 8 Nm.
95. Insert detent plate (82) with resilient linkage and push in shaft (76).
96. Screw in hexagon socket bolt (82a) and tighten to 8 Nm.
97. Fit on spacer sleeve (124) and the available shims (77).
Note:
Fit on spacer sleeve with the recess on the inside facing snap ring.
98. Fit roller (81) onto resilient linkage (82).
99. Fit on plastic guide (80) and press into locating hole.
100. Fit on parking pawl (74), insert spreader spring (75) and attach to parking pawl.
101. Fit on parking lock gear (73), ensuring that the two studs on the helical gear engage in the holes (arrows).
102. On transmission with pressed-on pulse disc (arrow) for electric speedometer, fit on parking lock gear (73) with pulse disc already pressed on.
103. Measure end play (c) of output shaft (clutch K2) and compensate.
Determining dimension "a".
Place measuring disc (028) onto sealing face of rear cover. Measure with the depth gauge from measuring disc (028) to ball bearing inner race (67).
Determining dimension "b".
Fit on measuring disc (028) and joint flange (64), tighten collar nut (62) to 100 Nm. Engage parking pawl to prevent parts moving. Fit gasket (72).
Measure with the depth gauge from measuring disc (028) to gasket (72).
Dimension "b" subtracted from dimension "a" produces the end play "c".
Adjust end play "c" by inserting or removing shims (77) below the parking lock gear (73) to 0.3 ± 0.1 mm.
104. On transmission with mechanical speedometer push gasket (arrow) onto the oil pipe (102) and insert oil pipe.
105. Fit on helical gear for speedometer drive (125) and ensure that the two studs engage in the holes in parking lock gear (73).
106. Assemble and fit on rear cover (70),tighten bolts (71) to 13 Nm.
107. Insert washer (65).
108. Insert O-ring (63) into joint flange (64).
109. Fit on joint flange (64), tighten twelve-point collar nut (62) to 120 Nm.
110. Knock collar of twelve-point collar nut (62) into recess of output shaft (arrow) with a suitable drift.
111. Screw in kick-down solenoid valve (61) and tighten to 20 Nm.
Socket 126 589 02 09 00
112. Insert modulating pressure control valve (59) and thrust pin (59a).
Note:
As from end no.2201 in transmissions 722.402 and 722.407, a spring is installed.
113. Fit on vacuum unit (60) together with retaining plate (57), tighten hexagon socket bolts (58) to 8 Nm.
114. Fit on starter lock-out switch (53); ensuring that driver engages in range selector lever. Screw in both bolts (55), but do not tighten.
Insert a 4 mm split pin or bit as locating pin (93) through the locating hole into the driver of the starter lock-out switch (53). Tighten bolts (55) to 8 Nm and pull out locating pin.
115. Insert lip seal (39) at brake band piston B1 (37) in such a way that seal lip is pointing in the direction of the arrow.
Note:
Transmissions 722.403/404/407 have a brake band piston B1 with reduced diameter (56 mm). The brake band piston cover (40) is designed as an insert and accommodates the B1 piston (37).
Measure play "L" at brake band B1; it does not change.
As from transmission end no. 346 389, a brake band piston with removable thrust pin is installed. The play is set with shims, which are available in the 3 thicknesses 0.5, 1.0 and 1.5.
37. Brake band piston B1
38. Thrust pin
39 Lip seal
136 Shims
137 O-ring
a max. 6.5 mm
116. Fit on assembly device (026) 3nd bolt to transmission housing.
117. Insert brake band piston B1 (37) together with compression springs (35 and 36) and measuring device (031).
118. Screw in spindle of assembly device (026) ensuring that thrust pin of brake band piston B1 (37) is inserted into brake band and lip seal (39) is not damaged.
031 Measuring device 201 589 07 21 0O
119. Insert retaining ring, release pressure on assembly device (026) and remove.
120. Measuring and adjusting play "1" at brake band B1.
Note:
The thread on measuring device (031) has a 1 mm pitch so that one revolution means 1 mm travel.
Screw in bolt on measuring device (031) by hand until a resistance is felt.
For brake band pistons with removable thrust pin, use a bolt without measuring tip.
Screw in bolt further using a torque wrench, counting the number of rotations and tightening bolt to 1 Nm.
Idle travel at brake band must equal 1.8 - 2.4 mm; in other words, after 1.8 -2.4 rotations a torque of 1 Nm must be reached.
If idle travel is excessive, install a brake band piston with longer thrust pin or, if idle travel is too small, install a brake band piston with shorter thrust pin.
121. Fit on assembly device (026) again and bolt tight. In place of measuring device (031), install brake band piston cover (40), then take off assembly device (026).
122. Insert thrust pin thrust bearing B2 (28) with the large diameter facing brake band B2 (27).
123. Insert thrust pin (26) into brake band piston B2 (15)
Note:
Thrust pins (26) are available in 5 lengths for compensating for idle travel at brake band B2.
